Quality & Engineering Track

Saturday, April 16 Sunday, April 17 Monday, April 18

Saturday, April 16

8 a.m.-9 a.m. 

Energy Conservation at Grede Foundry (16-174)
All metals • All processes
Larry Foreman, Grede Holdings LLC

This presentation will describe how Grede reduced energy use and provide practical suggestions for saving energy in melting and other foundry processes.

9:15 a.m.-10:15 a.m.

Molding Methods & Materials Silver Anniversary Lecture: Methylene Blue Determination of Clay: It’s Not Your Father’s Test Anymore (16-004) 
All metals • Sand
Vic LaFay & Stephen Neltner, IMERYS

The evaluation of foundry clays has come a long way since 1990 when the original paper was presented at the AFS Casting Congress. The evaluation of green sand molding properties with the additional contribution of the Methylene Blue testing protocol has allowed metalcasting facilities to apply laboratory information to the successful running of their operations.

Traceability of Height Measurements on Green Sand Molds Using 3D-Optical Scanning (16-033) 
All metals • Green sand
Kamran Mohaghegh, Seyed Alireza Yazdanbakhsh, Niels Skat Tiedje & Leonardo De Chiffre, Technical University of Denmark

The surface of the green sand mold is not suitable for measurements using a tactile coordinate measuring machine. A metrological approach for measurement using an optical 3D scanner will be presented.

Sunday, April 17

8 a.m.-9 a.m.

Data on the Performance Effect of Blow Tube Design (16-052) 
All metals • Sand
Andrew Pike, Jesus Benavente & Kathleen Lowe, ASK Chemicals

Cores blown with both straight and neck-down blow tubes under controlled laboratory conditions were analyzed and compared by high speed photography, core weight recordings, and visual observations. The data gathered shows that minimal design choices can have a significant impact on core quality.

9:15 a.m.-10:15 a.m.

Austempered Ductile Iron—Beyond the Standard (16-098) 
Iron • Sand
John Keough, Kathy Hayrynen, & Vasko Popovski, Applied Process Inc.; Justin Lefevre, Joyworks LLC

The authors will explore the critical issues related to substandard and properly made austempered ductile iron (ADI) so both the engineering and technical purchasing communities may benefit from properly specified and certified ADI components.

High Strength Ductile Iron Produced by Engineered Cooling: Application for Different Casting Processes (16-048) 
Iron • Sand
Simon Lekakh, Brenton Hrebec, Robby Scott, & Joshua Schlobohm, Missouri University of Science and Technology

The development of high strength ductile iron castings in as-cast conditions by applying an engineered cooling will be investigated in this session. The possible strengthening level as well as process limitations will be discussed.

Additive Manufacturing (16-151)
All metals • All processes
Oliver Johnson, Tooling and Equipment International Corp; Aaron Kepler, Caterpillar Inc.; Jerry Thiel, University of Northern Iowa, Metal Casting Center

Practical use of additive manufacturing currently used in the metalcasting facility and what’s coming in the future will be discussed.

Predicting Casting Dimensions With Computer Process Modeling (16-076) 
All metals • All processes
Jerry Thiel, Sairam Ravi, University of Northern Iowa, Metal Casting Center

Research has detailed a methodology using computer process modeling to accurately determine casting dimensions from room temperature pattern dimensions. As the ability of creating castings true to designs improves, reductions in machine stock can be made to decrease cost, improve reliability and speed production.

1:30 p.m.-3 p.m.

Controlling Exposures to Air Contaminants in Metalcasting–A Performance-Based Approach (16-062) 
All  metals • All processes
Thomas Slavin, Cardno ChemRisk; Robert Scholz, TRC Environmental Corporation

This presentation will provide foundries with up-to-date industrial hygiene control guidelines so they can implement exposure control programs that are effective, reliable and feasible. 

3:15 p.m.-4:45 p.m.

Metallurgical Properties Inside a Sand Molded Aluminum 206 Casting (16-002) 
Aluminum • Sand
Franco Chiesa, David Levasseur & Jeremy Carignan, Centre de Métallurgie du Québec; Bernard Duchesne, Collège de Trois-Rivières 

This presentation will share the results of a metallurgical study of aluminum alloy 206 in the T4 and T7 condition.

The Background, Use and Application of the Cast Iron Strain Life Fatigue Database (16-090)
Iron • Sand
John Tartaglia, Element Materials Technology; Jiten Shah, Product Development & Analysis LLC; Tony Lindert, Oshkosh Corporation

Panelists will present on the data collection and testing process used to create the Strain Life Fatigue database. They also will cover how to use this information in design applications along with OEM practical examples.

3D Scanning: Developing Industry Accepted Methodology (16-149)
All metals • All processes
Nick Fox, Galesburg Castings Inc.; Shaun Thomas, Dotson Foundry; Ron Spencer, Rochester Metals Products

This panel will give an update on the development of a uniform method of implementing 3D scanning technology throughout the industry. The technology can be a valuable tool for dimensional reporting and comparison of tooling, castings and cores.

Monday, April 18

8 a.m.-9 a.m.

Low Pressure Diecasting Simulation Discovery Through Short Shot (16-045) 
Nonferrous • Permanent mold, diecasting
Melissa Carter, Flow Science Inc.; Tim Kauffung, Lucas Weyenberg & Chris Peters, Versevo Inc.

This paper will focus on how to apply the correct assumptions and boundary conditions to the simulation software in order to accurately predict the correct input parameters in low pressure diecasting (permanent mold).

Autonomous Optimization of Die Casting Processes (16-040) 
Nonferrous • Diecasting
Deepika Gaddam, MAGMA Foundry Technologies Inc.

This session will show examples of high pressure die castings where autonomous optimization options were utilized to resolve casting defect issues.

Maintenance Practices for Operational & Energy Savings in the Foundry (16-094)
All  metals • All processes
Al Gambsky, Aarrowcast, Inc.; Howard Wood, Kodiak Group

This panel will discuss the improvements to operations and energy costs saving through new or alternative technologies. The implementation of a predictive maintenance program to better anticipate undesirable system conditions and improving equipment life, creating energy savings, and increasing production will be addressed.

9:15 a.m.-10:15 a.m.

Maintenance and R&D Cost Recovery (16-147)
All metals • All processes
Lester Cook, KBKG; Michael Maroney, KBKG, Inc.; Brian Reinke, TDI Energy Solutions

The panel will review and discuss an alternative approach that may allow you to take such expenses as furnace relining, maintenance and other capital equipment in the year they are incurred. 

1:30 p.m.-3 p.m.

Non-Destructive Testing for Aging in Gray Cast Iron (16-017) 
Iron • Sand
Kevin Kuehl, Matthew Schultz & Nickolas Meyer, Waupaca Foundry

While prior research has indicated an increase in strength from aging in gray cast iron, tensile testing does not have the precision required to detect small changes in value. Non-destructive techniques of resonant frequency and ultrasonic velocity testing demonstrated very good precision, and were able to detect small changes resulting from room temperature aging. 

Application of Resonance Inspection to Cast Iron—Literature Review (16-053) 
Iron • Sand
Siddhartha Biswas & Charles Monroe, University of Alabama at Birmingham

Existing literature on the application of resonance inspection of cast iron will be reviewed and critical issues for future research in the area of resonance inspection and defect identification will be discussed.

Improving Casting Quality and Productivity Through the Application of a High Efficiency, Engineered Lustrous Carbon Former (16-057) 
All metals • Sand
Nick Richardson; Vic LaFay, IMERYS

A properly designed lustrous carbon former for the foundry industry can be engineered through the selection and blending of high efficiency coals. This presentation will demonstrate how the conversion of a sand system was performed, resulting in improved casting quality measured in scrap reduction and improved productivity.

Non-Standard Testing to Qualify 3D Printed Sands (16-066) 
All metals • Sand
Sam Ramrattan, Western Michigan University; Terrence Senish & Mihaela Nastac, ExOne 

The purpose of this study is to characterize post cured 3D printed silica sand specimens with non-standard tests designed to measure the physical, mechanical and thermo-mechanical properties as required for castability. 

New Method for Measuring Gas Evolution in Chemically Bonded Sands (16-058) 
All metals • Sand
Sairam Ravi & Jerry Thiel, University of Northern Iowa, Metal Casting Center 

In this research, a new gas evolution test method was developed which uses a thermos gravimetric analysis unit in conjunction with the atomic weights of the gaseous products to calculate the gas volume and associated gas pressure based on the mold or core permeability. 

3:15 p.m.-4:45 p.m.

Casting Inspection Measurement and Machining (16-150)
All metals • All processes
Frank Peters, Iowa State University; Jiten Shah, Product Development & Analysis LLC; Andy Bowman, Caterpillar Inc.

The panel will discuss visual casting inspection, how good it is and the development of inspection standards and adaptive machining fixtures. A scanned casting versus a coordinate measuring machine dimensional layout of a casting will be compared for PPAP. 

Autonomous Optimization of Gating and Risering Design for Steel Castings (16-039) 
Steel • Sand
Roy Stevenson, MAGMA Foundry Technologies Inc.

This session will detail a novel simulation software, autonomous optimization which greatly reduces the amount of time required to set up and analyze individual simulations.